Resin-attached lead frame, method for manufacturing the same, and lead frame

ABSTRACT

A resin-attached lead frame includes a lead frame main body having a plurality of die pads (LED element resting portions) and a plurality of lead portions spaced from the die pads, the lead frame main body further including LED element resting regions each formed over an area including an upper surface of each of the die pads and an upper surface of each of the lead portions. A reflecting resin section surrounds each LED element resting region of the lead frame main body. A vapor-deposited aluminum layer or a sputtered aluminum layer is provided on respective upper surfaces of the LED element resting regions of the lead frame main body.

TECHNICAL FIELD

The present invention relates to a resin-attached lead frame used forresting LED elements thereupon, to a method for manufacturing the leadframe, and to a lead frame.

BACKGROUND ART

In recent years, optical devices, especially LED devices, are expandingtheir applications as illumination for cellular phones, or as backlightsfor liquid crystals. These applications are expanding to the generallighting or illumination recently replacing incandescent light bulbs. Ingeneral, however, the light-emission efficiency of LED devices in onewafer has a tendency to vary significantly. In addition, these LEDdevices are still too low in light-emission efficiency to find their usein general lighting/illumination applications, and thus a plurality ofLED elements need to be mounted in one LED device.

Among the packaging techniques for these LED devices are one in whichLED elements are mounted on an organic substrate of a glass epoxy or thelike and after wire bonding, the LED elements are sealed with anepoxy-based transparent resin and then separated into individual piecesusing a method called singulation. In another packaging technique, areflecting plate formed from a white resin such as polyphthalamide (PPA)is molded as a reflecting resin portion on a ceramic substrate, thenafter LED elements have been mounted on the reflecting plate andwire-bonded, the LED elements are sealed with an epoxy-based transparentresin and separated into individual pieces by singulation. In yetanother technique, a reflecting plate is molded with a white resin, suchas PPA, on a lead frame, then after LED elements have been mounted onthe reflecting plate and wire-bonded, the LED elements are sealed with atransparent resin and separated into individual pieces by singulation.

PRIOR ART LITERATURE Patent Documents

Patent Document 1: JP-A-2005-136379

As outlined above, for improved light-extraction efficiency (luminousflux) of an LED package, a premolding of a reflecting plate formed froma synthetic resin is used as a substrate on which LED elements are to bemounted. Traditionally, lead frames having a totally silver-platedsurface to enhance their light-reflection efficiency are also used.Depending upon the type of synthetic resin constituting the reflectingplate, however, the ultraviolet rays emitted from the LED elements maycause yellowish discoloration due to deterioration, thus resulting inlight extraction efficiency decreasing over time. Additionally, thesilver plating of the lead frame causes a reaction with the hydrogensulfide contained in air, and leads to brownish discoloration.

The present invention has been made with the above taken intoconsideration, and an object of the invention is to provide aresin-attached lead frame, its manufacturing method, and lead frameadapted to enhance extraction efficiency of light emissions from LEDelements included in a semiconductor device, and to prevent the leadframe from degrading with time.

SUMMARY OF THE INVENTION

A first aspect of the present invention is a resin-attached lead frame,comprising: a lead frame main body including a plurality of LED elementresting portions and a plurality of lead portions each spaced from thecorresponding one of the LED element resting portions, the lead framemain body further including LED element resting regions each formed overan area including an upper surface of each of the LED element restingportions and an upper surface of each of the lead portions; and areflecting resin section surrounding each of the LED element restingregions of the lead frame main body; wherein a vapor-deposited aluminumlayer or a sputtered aluminum layer is provided on respective uppersurfaces of the LED element resting regions of the lead frame main body.

A second aspect of the present invention is a resin-attached lead frame,comprising: a lead frame main body including an LED element restingportion and a lead portion disposed apart from the LED element restingportion, the lead frame main body further including an LED elementresting region formed over an area including an upper surface of the LEDelement resting portion and an upper surface of the lead portion; and areflecting resin section surrounding the LED element resting region ofthe lead frame main body; wherein a vapor-deposited aluminum layer or asputtered aluminum layer is provided on an upper surface of the LEDelement resting region of the lead frame main body.

In the resin-attached lead frame according to either of the first andsecond aspects of the present invention, the vapor-deposited aluminumlayer or the sputtered aluminum layer is further provided on an innerwall of the reflecting resin section as well.

In the resin-attached lead frame according to the first aspect of thepresent invention, the plurality of LED element resting regions of thelead frame main body are arranged lengthwise and breadthwise.

The lead frame main body of the resin-attached lead frame according toeither of the first and second aspects of the present invention isformed from any one of copper, a copper alloy, and a 42-alloy; wherein,of the lead frame main body, at least the upper surface of the LEDelement resting region is worked into a mirror-like finish having aroughness level of 0.01 μm to 0.10 μm in arithmetic average height “Sa”and 2 μm to 18 μm in roughness curvilinear element average length “Sm”.

In the resin-attached lead frame according to either of the first andsecond aspects of the present invention, a silver-plated layer isprovided on a lower surface of the lead portion as well as on a lowersurface of the LED element resting portion of the lead frame main body.

In the resin-attached lead frame according to either of the first andsecond aspects of the present invention, grooves for enhancing adhesionbetween the lead frame main body and the reflecting resin section areformed on an upper surface of the lead frame main body.

In the resin-attached lead frame according to either of the first andsecond aspects of the present invention, a reflecting metallic layer isprovided on an upper surface of the reflecting resin section.

In the resin-attached lead frame according to either of the first andsecond aspects of the present invention, the upper surface of thereflecting resin section has a part which is cut by dicing, thereflecting resin section is exposed at the part.

In the resin-attached lead frame according to either of the first andsecond aspects of the present invention, an inward concaved recess isformed on the upper surface of the reflecting resin section.

A third aspect of the present invention is a lead frame comprising: alead frame main body including a plurality of LED element restingportions and a plurality of lead portions each spaced from thecorresponding one of the LED element resting portions, the lead framemain body further including LED element resting regions each formed overan area including an upper surface of each of the LED element restingportions and an upper surface of each of the lead portions; wherein avapor-deposited aluminum layer or a sputtered aluminum layer is providedon respective upper surfaces of the LED element resting regions of thelead frame main body.

A fourth aspect of the present invention is a lead frame comprising: alead frame main body including an LED element resting portion and a leadportion disposed apart from the LED element resting portion, the leadframe main body further including an LED element resting region formedover an area including an upper surface of the LED element restingportion and an upper surface of the lead portion; wherein avapor-deposited aluminum layer or a sputtered aluminum layer is providedon an upper surface of the LED element resting region of the lead framemain body.

A fifth aspect of the present invention is a method for manufacturing aresin-attached lead frame, the method comprising the steps of: providinga lead frame main body including a plurality of LED element restingportions and a plurality of lead portions each spaced from thecorresponding one of the LED element resting portions, the lead framemain body further including LED element resting regions each formed overan area including an upper surface of each of the LED element restingportions and an upper surface of each of the lead portions; providing avapor-deposited aluminum layer or an sputtered aluminum layer onrespective upper surfaces of the LED element resting regions of the leadframe main body; and providing a reflecting resin section surroundingeach of the LED element resting regions of the lead frame main body.

A sixth aspect of the present invention is a method for manufacturing aresin-attached lead frame, the method comprising the steps of: providinga lead frame main body including a plurality of LED element restingportions and a plurality of lead portions each spaced from thecorresponding one of the LED element resting portions, the lead framemain body further including LED element resting regions each formed overan area including an upper surface of each of the LED element restingportions and an upper surface of each of the lead portions; providing areflecting resin section surrounding each of the LED element restingregions of the lead frame main body; and providing a vapor-depositedaluminum layer or a sputtered aluminum layer on an inner wall of thereflecting resin section as well as on respective upper surfaces of theLED element resting regions of the lead frame main body.

In accordance with the present invention, the vapor-deposited aluminumlayer or the sputtered aluminum layer is provided on the upper surfacesof each LED element resting region of the lead frame main body. Thisachieves efficient reflection of light from LED elements and enhancesextraction efficiency of the light from each LED device, while at thesame time preventing the lead frame from degrading with time.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of a lead frame according to a firstembodiment of the present invention, the sectional view being takenalong line I-I in FIG. 2;

FIG. 2 is a plan view showing the lead frame according to the firstembodiment of the present invention;

FIG. 3 is a sectional view of the resin-attached lead frame according tothe first embodiment of the present invention, the sectional view beingtaken along line in FIG. 4;

FIG. 4 is a plan view showing the resin-attached lead frame according tothe first embodiment of the present invention;

FIG. 5 is a sectional view of a semiconductor device relating to thefirst embodiment of the present invention, the sectional view beingtaken along line V-V in FIG. 6;

FIG. 6 is a plan view of the semiconductor device relating to the firstembodiment of the present invention;

FIG. 7(a) to (g) shows steps for manufacturing the lead frame accordingto the first embodiment of the present invention;

FIG. 8(a) to (c) shows further steps for manufacturing theresin-attached lead frame according to the first embodiment of thepresent invention;

FIG. 9(a) to (f) shows steps for manufacturing the semiconductor deviceaccording to the first embodiment of the present invention;

FIG. 10 is a sectional view showing the semiconductor device disposed onan electrical interconnection substrate;

FIG. 11 is a sectional view of a resin-attached lead frame according toa second embodiment of the present invention, the sectional view beingtaken along line XI-XI in FIG. 12;

FIG. 12 is a plan view showing the resin-attached lead frame accordingto the second embodiment of the present invention;

FIG. 13 is a sectional view of a semiconductor device relating to thesecond embodiment of the present invention, the sectional view beingtaken along line XIII-XIII in FIG. 14;

FIG. 14 is a plan view of the semiconductor device relating to thesecond embodiment of the present invention;

FIG. 15(a) to (f) shows steps for manufacturing the lead frame accordingto the second embodiment of the present invention;

FIG. 16(a) to (d) shows further steps for manufacturing theresin-attached lead frame according to the second embodiment of thepresent invention;

FIG. 17 is a sectional view showing a modification of the resin-attachedlead frame according to the second embodiment of the present invention;

FIG. 18 is a sectional view showing another modification of theresin-attached lead frame according to the second embodiment of thepresent invention;

FIG. 19 is a sectional view showing yet another modification of theresin-attached lead frame according to the second embodiment of thepresent invention; and

FIG. 20 is a sectional view showing a further modification of theresin-attached lead frame according to the second embodiment of thepresent invention.

MODE FOR CARRYING OUT THE INVENTION First Embodiment

Hereunder, a first embodiment of the present invention will be describedreferring to FIGS. 1 to 10.

Lead Frame Configuration

First, a lead frame for resting LED elements, according to the presentembodiment is outlined below per FIGS. 1 and 2. FIGS. 1 and 2 are across-sectional view, and a plan view, respectively, of the lead frameaccording to the present embodiment.

The lead frame 15 shown in FIGS. 1 and 2 includes a lead frame main body11 having a plurality of LED element resting regions 14, and metalliclayers 12 provided on upper surfaces of the LED element resting regions14 of the lead frame main body 11, the metallic layers 12 eachfunctioning as a reflecting layer for reflecting light emitted from anLED element 21.

The lead frame main body (hereinafter referred to simply as the leadframe body) 11 is formed from a sheet of metal. The metal sheetconstituting the lead frame body 11 can be of a material such as copper,copper alloy, or 42-alloy (a Fe alloy with a 42% Ni content). Thicknessof the lead frame body 11 depends on a configuration of a semiconductordevice. Preferable thickness, however, ranges between 0.1 mm and 0.5 mm,inclusive.

In addition, as shown in FIG. 2, the lead frame body 11 has an outerframe 13, and the plurality of LED element resting regions 14 arearranged lengthwise and breadthwise inside the outer frame 13. The leadframe body 11 further includes a plurality of die pads (LED elementresting portions) 25 and a plurality of lead portions 26 each spacedfrom one of the die pads 25, and each LED element resting region 14 isformed over upper surfaces of one die pad 25 and one lead portion 26. Aspace 17 to be filled in with the reflecting resin section 23 is formedbetween the die pad 25 and the lead portion 26. The die pad 25 and thelead portion 26 are coupled to another adjacent die pad 25 and anotheradjacent lead portion 26, respectively, or to the outer frame 13, via anindependent, rod-shaped tie bar 16.

As shown in FIG. 1, a first outer lead portion 27 is formed on a lowersurface of the die pad 25, and a second outer lead portion 28 is formedon a lower surface of the lead section 26. On each of the first outerlead portion 27 and the second outer lead portion 28, a silver-platedlayer 29 is provided to enhance a degree of contact with solder. Theplated layer 29 is preferably 2 μm to 10 μm thick.

Each metallic layer 12 may be formed by, for example, vapor depositionor sputtering, and examples of a material constituting the metalliclayer can be aluminum, silver, rhodium, palladium, platinum, copper, andthe like. An example in which the metallic layer 12 is formed from avapor-deposited aluminum layer or a sputtered aluminum layer isdescribed below (hereinafter, this metallic layer is also referred tosimply as the vapor-deposited aluminum layer or sputtered aluminum layer12). The vapor-deposited aluminum layer or sputtered aluminum layer 12,functioning as a layer for reflecting the light from the LED element 21,is positioned on the uppermost surface side of the lead frame 15. Thevapor-deposited aluminum layer or sputtered aluminum layer 12 is formedby vacuum-vapor-depositing aluminum or sputtering aluminum. Thevapor-deposited aluminum layer or sputtered aluminum layer 12 is formedto have an extremely small thickness. More specifically, the thicknesspreferably ranges between 0.1 μm and 1.0 μm, inclusive. Thevapor-deposited aluminum layer or sputtered aluminum layer 12 may beformed directly on the lead frame body 11, but may be formed thereuponvia a bonding layer formed from, for example, a layer plated with silver(Ag).

In addition, although the vapor-deposited aluminum layer or sputteredaluminum layer 12 in the present embodiment is provided on an entireupper surface of the lead frame body 11 that includes the outer frame 13and the tie bars 16, the vapor-deposited aluminum layer or sputteredaluminum layer 12 needs only to be formed at least in the LED elementresting regions 14 on the upper surface of the lead frame body 11. Thisis because the LED element resting regions 14, not shrouded by thereflecting resin section 23 (described later herein) of the lead framebody 11, are sections that contribute to reflecting the light from eachLED element 21.

In another example, the vapor-deposited aluminum layer or sputteredaluminum layer 12 may be absent on a section of the lead frame bodysurface that is subjected to wire bonding.

In yet another example, the vapor-deposited aluminum layer or sputteredaluminum layer 12 may be absent on a section of the lead frame bodysurface that is subjected to the mounting of an LED element 21.

In a further example, while the vapor-deposited aluminum layer orsputtered aluminum layer 12 may be provided on the upper surface of thelead frame body 11 via a bonding layer (not shown) formed from asilver-plated layer, the vapor-deposited aluminum layer or sputteredaluminum layer 12 may not be provided on a section of the lead framebody surface that is subjected to wire bonding.

In a further example, while the vapor-deposited aluminum layer orsputtered aluminum layer 12 may be provided on the upper surface of thelead frame body 11 via a bonding layer (not shown) formed from asilver-plated layer, the vapor-deposited aluminum layer or sputteredaluminum layer 12 may not be provided on a section of the lead framebody surface that is subjected to the mounting of an LED element 21.

In a further example, of the lead frame body 11, at least upper surfacesof each LED element resting region 14 are preferably preworked into amirror-like finish before the vapor-deposited aluminum layer orsputtered aluminum layer 12 is provided on the upper surfaces.Preferable surface roughness of the LED element resting region 14 inthis case is such that surface roughness of the LED element restingregion 14 as measured using the Optical Surface & Layer Profiling SystemVertScan 2.0 (manufacturer: Ryoka Systems Inc.) will range between 0.01μm and 0.10 μm, inclusive, in arithmetic average height “Sa” and between2 μm and 18 μm, inclusive, in roughness curvilinear element averagelength “Sm”. This will increase a reflectance of the vapor-depositedaluminum layer or sputtered aluminum layer 12 formed on the uppersurface of the LED element resting region 14, and thereby achieve moreefficient reflection of the light from the LED element 21.

Furthermore, grooves 18 for enhancing adhesion between the lead framebody 11 and the reflecting resin section 23 are formed on the uppersurface of the lead frame body 11. The grooves 18, each having arectangular shape in a plane view (except at the space 17), are providedalong an outer edge of the LED element resting region 14 on the uppersurface of the lead frame body 11.

Reference symbol S (double-dotted chain line) in FIG. 2 denotes a regionof the lead frame 15 that corresponds to the semiconductor device 20(see FIGS. 5 and 6) detailed later herein.

While in the present embodiment the lead frame body 11 includes aplurality of die pads 25 and a plurality of lead portions 26 spaced fromone of the die pads 25, the lead frame body 11 is not limited to thisconfiguration and needs only to include at least one die pad 25 and onelead portion 26.

Resin-Attached Leaf Frame Configuration

Next, a resin-attached lead frame for resting LED elements according tothe present embodiment is outlined below per FIGS. 3 and 4. FIGS. 3 and4 are a cross-sectional view, and a plan view, respectively, of theresin-attached lead frame according to the present embodiment. In FIGS.3 and 4, the same elements as those shown in FIGS. 1 and 2 are eachassigned the same reference number or symbol.

The resin-attached lead frame 10 shown in FIGS. 3 and 4 is used to restLED elements 21 (see FIGS. 5 and 6). The resin-attached lead frame 10includes a lead frame 15 and a reflecting resin section 23 provided onthe lead frame 15 and surrounding LED element resting regions 14.

The lead frame 15 includes a lead frame body 11, and the lead frame body11 includes a plurality of die pads 25 and a plurality of lead portions26 each spaced from one of the die pads 25. An LED element restingregion 14 is formed over upper surfaces of each die pad 25 and each leadportion 26. The lead frame body 11 also has a vapor-deposited aluminumlayer or sputtered aluminum layer 12 on upper surfaces of each LEDelement resting region 14. In FIG. 4, the vapor-deposited aluminum layeror sputtered aluminum layer 12 is shown in hatched form. The lead frame15 is substantially of the same configuration as that shown in FIGS. 1and 2, and detailed description of the lead frame configuration istherefore omitted herein.

The reflecting resin section 23 is integrated with the lead frame 15 andhas a recess 23 a having a substantially rectangular shape in a planeview and surrounding the LED element 21. Inner walls 23 b are formed onthe inside of the recess 23 a. A space 17 filled in with the reflectingresin section 23 also exists between each die pad 25 and each leadportion 26. Details of the reflecting resin section 23 are describedlater herein.

While in the present embodiment the lead frame body 11 includes aplurality of die pads 25 and a plurality of lead portions 26 spaced fromthe corresponding die pad 25, the lead frame body 11 is not limited tothis configuration and needs only to include at least one die pad 25 andone lead portion 26.

Semiconductor Device Configuration

Next, a semiconductor device fabricated using the resin-attached leadframe shown in FIGS. 2 and 3 is described below per FIGS. 5 and 6. FIGS.5 and 6 are a cross-sectional view, and a plan view, respectively, ofthe semiconductor device (SON type) according to the present embodiment.In FIGS. 5 and 6, the same elements as those shown in FIGS. 1 to 4 areeach assigned the same reference number or symbol.

As shown in FIGS. 5 and 6, the semiconductor device 20 includes a(singulated) lead frame 15 having a lead frame body 11 and avapor-deposited aluminum layer or sputtered aluminum layer 12, an LEDelement 21 rested on a die pad 25 of the lead frame 15, and a bondingwire (electric conductor) 22 that electrically interconnects the LEDelement 21 and a lead portion 26 of the lead frame 15. Thevapor-deposited aluminum layer or sputtered aluminum layer 12 is shownin hatched form in FIG. 6.

In addition, a reflecting resin section 23 with a recess 23 a isprovided around the LED element 21. The LED element 21 and the bondingwire 22 are integrally sealed with a light-transmissive sealing resin24. The recess 23 a in the reflecting resin section 23 is filled withthe sealing resin 24. Of the lead frame body surface, a region in whichthe sealing resin 24 is provided corresponds to the LED element restingregion 14.

Members that constitute the semiconductor device 20 are described inorder below.

The lead frame 15 includes the lead frame body 11 having, as describedabove, the die pad 25 and the lead portion 26, and the vapor-depositedaluminum layer or sputtered aluminum layer 12 provided on the lead framebody 11 and functioning as a layer for reflecting light emitted from theLED element 21.

If a material formed from compound semiconductor single crystals such asGaP, GaAs, GaAlAs, GaAsP, AlInGaP, and/or InGaN, is appropriatelyselected for a light-emitting layer, a light-emission wavelength rangingbetween those of ultraviolet light and those of infrared light,inclusive, can be selected for the LED element 21. A commonly usedconventional element can be used as such an LED element 21.

The LED element 21 is fixedly mounted on the die pad 25 (vapor-depositedaluminum layer or sputtered aluminum layer 12), inside the recess 23 aof the reflecting resin section 23, via solder or a die-bonding paste.If a die-bonding paste is to be used, the die-bonding paste can be thatformed from a light-resistant epoxy resin or silicone resin.

The bonding wire 22 is formed from a highly electroconductive materialsuch as gold, with one end thereof being connected to a terminal section21 a of the LED element 21, and with the other end thereof beingconnected to an upper surface (on the vapor-deposited aluminum layer orsputtered aluminum layer 12) of the lead portion 26.

The reflecting resin section 23 is formed by, for example,injection-molding a thermoplastic resin over the resin-attached leadframe 10 or by, for example, injection-molding or transfer-molding athermosetting resin over the resin-attached lead frame 10. Thereflecting resin section 23 can vary in shape according to a design of amold used during the injection molding or transfer molding of the resin.For example, the entire reflecting resin section 23 can be formed into aregularly parallelepipedic shape as shown in FIGS. 5 and 6, or formedinto a shape of a cylinder, pyramid/cone, or the like. The recess 23 acan have, for example, either a rectangular, circular, elliptical, orpolygonal base. The inner walls 23 b of the recess 23 a may have eithera rectilinear cross-sectional shape as shown in FIG. 5, or have acurvilinear one.

A material excelling particularly in heat resistance, weatherability,and mechanical strength is desirably selected for the thermoplasticresin or thermosetting resin used in the reflecting resin section 23.The useable kinds of thermoplastic resin materials are polyamide,polyphthalamide (PPA), polyphenylene sulfide, liquid-crystal polymers,polyether sulphone, polyetherimide, polybutylene terephthalate,polyolefin, cyclopolyolefin, and the like. The useable kinds ofthermosetting resin materials are silicone, epoxies, polyimides, and thelike. If either of titanium dioxide, zirconium dioxide, potassiumtitanate, aluminum nitride, and boron nitride is added as alight-reflecting agent to the resin, this increases a reflectance of thelight from the light-emitting element, at the base and inner walls 23 bof the recess 23 a, thus increasing light-extraction efficiency of theentire semiconductor device 20.

For enhancing light-extraction efficiency, a material high in an indexof refraction as well as in light transmittance at a light-emissionwavelength of the semiconductor device 20 is desirably selected as thesealing resin 24. An epoxy resin or a silicone resin can therefore beselected as a resin that satisfies high heat resistance, weatherability,and mechanical strength requirements. To use a high-luminance LED, inparticular, as the LED element 21, the sealing resin 24 is preferablyformed from a highly weatherable silicone resin material since thesealing resin 24 is exposed to strong light.

Method of Manufacturing the Lead Frame and the Resin-Attached Lead Frame

Next, a method of manufacturing the lead frame 15 shown in FIGS. 1 and2, and the resin-attached lead frame 10 shown in FIGS. 3 and 4 aredescribed below using FIGS. 7(a) to (g) and 8(a) to (c).

First as shown in FIG. 7(a), a metallic substrate 31 of a flat-plateshape is provided. As outlined above, the metallic substrate 31 can bethat formed from copper, a copper alloy, a 42-alloy (a Fe alloy with a42% Ni content), and/or the like. Both sides of the metallic substrate31 are preferably degreased and cleaned beforehand.

In addition, the metallic substrate 31 preferably has its upper surface31 a preworked into a mirror-like finish to have a roughness level of0.01 μm to 0.1 μm in arithmetic average height “Sa” and 2 μm to 18 μm inroughness curvilinear element average length “Sm”. Examples of suchmirror-like finishing methods can be by using a mirror-like finishingroller during final rolling of the material, or by conductingdouble-side mirror-like copper plating.

Next as shown in FIG. 7(b), entire upper and lower surfaces of themetallic substrate 31 are coated with photosensitive resists 32 a and 33a, respectively, and then the resists are dried. The photosensitiveresists 32 a, 33 a can be conventionally known ones.

Following the above, light exposure of the metallic substrate 31 via aphotomask takes place, and developing further follows. Etching resistlayers 32 and 33 with desired openings 32 b and 33 b, respectively, arethen formed as shown in FIG. 7(c).

Next as shown in FIG. 7(d), etching of the metallic substrate 31 with anetchant occurs using the etching resist layers 32, 33 as anti-etchingfilms. An appropriate chemical as the etchant can be selected accordingto the kind of metallic substrate material to be used. For example, touse copper as the material of the metallic substrate 31, the substratecan usually be spray-etched from both sides using an aqueous ferricchloride solution.

After that, the etching resist layers 32, 33 are peeled off, whereby thelead frame body 11 with die pads 25 and lead portions 26 spaced from thedie pads 25 will then be obtained as shown in FIG. 7(e). Providing halfetching at this time will also form grooves 18 on the upper surface ofthe lead frame body 11.

Next, the lower surface of the lead frame body 11 is provided withelectrolytic plating to deposit a metal (silver) onto a first outer leadportion 27 and a second outer lead portion 28, thus forming a platedlayer 29 for enhanced contact with the solder. This state is shown inFIG. 7(f). In this case, the lead frame body 11 goes through steps suchas electrolytic degreasing, pickling, chemical polishing, copperstriking, water washing, neutral degreasing, cyanide cleaning, andsilver plating, in that order. This forms the plated layer 29 on thefirst outer lead portion 27 and the second outer lead portion 28. Anelectroplating solution used in the silver-plating step can be, forexample, a silver-plating solution composed mainly of silver cyanide. Inan actual process, water washing is added between steps, as required.

Next, aluminum is vapor-deposited or sputtered onto the surface of thelead frame body 11, whereby as shown in FIG. 7(g), the vapor-depositedaluminum layer or sputtered aluminum layer 12 functioning as areflecting layer is formed on the entire surface of the lead frame body11 including the LED element resting region 14.

The formation of the vapor-deposited aluminum layer or sputteredaluminum layer is, more specifically, not limited to the above method,but in a case of vapor deposition, the vapor-deposited aluminum layer 12can be formed on the surface of the lead frame body 11 by usingparameters of 9×10⁻⁶ torr in maximum attainable degree of vacuum and 1.5nm/sec in deposition rate. In a case of sputtering, the sputteredaluminum layer 12 can be formed on the surface of the lead frame body 11by using parameters of 4×10⁻⁶ torr in maximum attainable degree ofvacuum, 5×10⁻³ torr in film-forming degree of vacuum, and 900 W insputtering power (for a target size of 5 inches by 18 inches).

In this way, the lead frame 15 with the lead frame body 11 and thevapor-deposited aluminum layer or sputtered aluminum layer 12 formed onthe lead frame body 11 is obtained. This state is shown in FIG. 7(g).

Next, the reflecting resin section 23 is formed on the vapor-depositedaluminum layer or sputtered aluminum layer 12 of the lead frame 15. Theformation of the reflecting resin section 23 is described in furtherdetail below.

First as shown in FIG. 8(a), the lead frame 15 that has been obtainedthrough the steps shown in FIG. 7(a) to (g) is mounted in a mold 35 ofan injection molding machine or transfer molding machine (not shown).Cavities 35 a appropriate for a shape of the reflecting resin section 23are preformed in the mold 35.

Next, a thermosetting resin is poured from a resin supply section (notshown) of the injection molding machine or transfer molding machine intothe mold 35 and then allowed to set. The reflecting resin section 23 isthen formed in a section of the lead frame surface, exclusive of the LEDelement resting region 14, as shown in FIG. 8(b). At this time, thereflecting resin section 23 is also generated in the space 17 betweenthe die pad 25 and the lead portion 26.

The lead frame 15 with the formed reflecting resin section 23 is removedfrom the mold 35 after that. In this way, the resin-attached lead frame10 (see FIGS. 3 and 4) with the reflecting resin section 23 and the leadframe 15 is obtained. This state is shown in FIG. 8(c).

Method of Manufacturing the Semiconductor Device

Next, a method of manufacturing the semiconductor device 20 shown inFIGS. 5 and 6 is described below using FIG. 9(a) to (f).

First, the resin-attached lead frame 10 with the lead frame 15 andreflecting resin section 23 described in the steps of FIGS. 7(a) to (g)and 8(a) to (c) is fabricated. FIG. 9(a) shows the fabricated lead frame10.

Next, an LED element 21 is mounted on the die pad 25 of the lead frame15. In this case, as shown in FIG. 9(b), the LED element 21 is rested onand fixed to the die pad 25 (the vapor-deposited aluminum layer orsputtered aluminum layer 12) of the lead frame 15 by use of solder or adie-bonding paste (this step is called die attaching).

Next as shown in FIG. 9(c), the terminal section 21 a of the LED element21 and an upper surface of the lead portion 26 are electricallyconnected to each other via a bonding wire 22 (this step is called wirebonding).

After this, the recess 23 a in the reflecting resin 23 is filled in witha sealing resin 24, whereby the LED element 21 and the bonding wire 22are sealed with the sealing resin 24. This state is shown in FIG. 9(d).

Next as shown in FIG. 9(e), the lead frame 15 is separated for each LEDelement 21 by dicing the sections of the lead frame 15 that correspondto the reflecting resin section 23 between the LED elements 21. At thistime, the lead frame 15 is first rested on and fixed to a dicing tape37, and then the reflecting resin section 23 between the LED elements 21is cut in a vertical direction using, for example, a blade 38 made of adiamond grinding wheel or the like.

The semiconductor device 20 shown in FIGS. 5 and 6 is thus obtained.FIG. 9(f) shows the semiconductor device 20 existing after thereflecting resin section 23 has been cut.

Operational Effects of the Present Embodiment

Next, operational effects of the present embodiment having the aboveconfiguration are described below using FIG. 10. FIG. 10 is a sectionalview showing the semiconductor device disposed on an electricalinterconnection substrate.

As shown in FIG. 10, the semiconductor device 20 according to thepresent embodiment is disposed on the interconnection substrate 41. Theinterconnection substrate 41 includes a substrate body 42 andinterconnection terminal sections 43 and 44 formed on the substrate body42. The terminal section 43 of the two interconnection terminal sectionsis connected to a first outer lead portion 27 via a connecting solderportion 45. The other terminal section 44 is connected to a second outerlead portion 28 via a connecting solder portion 46.

In this way, the semiconductor device 20 is disposed on theinterconnection substrate 41. In addition, when current is appliedbetween the paired interconnection terminal sections 43 and 44, thecurrent is further applied to the LED element 21 on the die pad 25, thusactivating the LED element 21.

At this time, light from the LED element 21 passes through the sealingresin 24 and is released from an upper surface of the sealing resin 24,or reflects from the inner walls 23 b of the recess 23 a in thereflecting resin section 23 and is released from the surface of thesealing resin 24. Alternatively, the light from the LED element 21reflects from the surface of the vapor-deposited aluminum layer orsputtered aluminum layer 12 and is released from the surface of thesealing resin 24.

In the present embodiment, the vapor-deposited aluminum layer orsputtered aluminum layer 12 is provided on the surface of the LEDelement resting region 14 of the lead frame body 11. This makes thelight from the LED element 21 reflect efficiently, hence enhancingextraction efficiency of the light from the LED element 21. In addition,the above prevents the lead frame 15 from degrading with time, since thealuminum constituting the vapor-deposited aluminum layer or sputteredaluminum layer 12 is free from degradation due to presence of hydrogensulfide in air.

As described above, in accordance with the present embodiment, thevapor-deposited aluminum layer or sputtered aluminum layer 12 isprovided on the surface of each LED element resting region 14 of thelead frame body 11. This makes the light from the LED element 21 reflectefficiently and hence enhances the extraction efficiency of the lightfrom the LED element 21. In addition, the above prevents the lead frame15 from degrading with time.

Furthermore, the provision of the vapor-deposited aluminum layer orsputtered aluminum layer 12 in the present embodiment raises adhesionbetween the lead frame 15 and the sealing resin 24. The state of wirebonding with the bonding wire 22 and the die attaching of the LEDelements 21 are also maintained at an appropriate level.

If the vapor-deposited aluminum layer or sputtered aluminum layer 12 isprovided via a bonding layer formed from a silver-plated layer, since onthe section subjected to wire bonding, the underlying silver (thesilver-plated layer) will break the thin aluminum and form an alloy ofthe silver and the wire, a further desirable bond will be obtained andstronger wire bonding attained.

If the vapor-deposited aluminum layer or sputtered aluminum layer 12 isnot provided on the section subjected to wire bonding, since energy forthe silver to break an oxide film of the aluminum during wire bonding isnot needed, a bonding temperature, parameters relating to use ofultrasonic waves, and other parameters can be alleviated.

If the vapor-deposited aluminum layer or sputtered aluminum layer 12 isnot provided on the section where the LED element 21 is to be mounted, aheat-releasing route via the die pad 25 becomes short, which results inimproved heat release characteristics.

For example, if the vapor-deposited aluminum layer or sputtered aluminumlayer 12 is provided via a bonding layer formed from a silver-platedlayer and not provided on the section subjected to wire bonding, since,the surface of the silver-plated layer can be directly wire-bonded as inconventional technology, a bond with a bonding wire 22 of gold, forexample, can be maintained at a high strength level.

For example, if the vapor-deposited aluminum layer or sputtered aluminumlayer 12 is provided via a bonding layer formed from a silver-platedlayer and not provided on the section where the LED element 21 is to bemounted, when the LED element 21 is to be connected by soldering, forexample, high wettability of the solder on that section generates novoid in the solder and allows reliable mounting of the entire LEDelement surface.

Second Embodiment

Next, a second embodiment of the present invention is described belowreferring to FIGS. 11 to 16. FIGS. 11 to 16 show the second embodimentof the present invention. The second embodiment shown in FIGS. 11 to 16differs from the first embodiment in that a vapor-deposited aluminumlayer or sputtered aluminum layer 12 is also provided on inner walls 23b of a reflecting resin section 23, and all other elements aresubstantially the same as those in the first embodiment. In FIGS. 11 to16, the same elements as those of the embodiment shown in FIGS. 1 to 10are each assigned the same reference number or symbol, and detaileddescription of these elements is omitted herein.

Resin-Attached Lead Frame Configuration

First, a resin-attached lead frame according to the present embodimentis outlined below per FIGS. 11 and 12. FIGS. 11 and 12 are across-sectional view, and a plan view, respectively, of theresin-attached lead frame according to the present embodiment.

As shown in FIGS. 11 and 12, the resin-attached lead frame 10A accordingto the present embodiment includes a lead frame 15 and a reflectingresin section 23.

The lead frame 15 includes a lead frame body 11, and the lead frame body11 includes a plurality of die pads 25 and a plurality of lead portions26 each spaced from one of the die pads 25. An LED element restingregion 14 is formed over upper surfaces of each die pad 25 and each leadportion 26. The reflecting resin section 23 is provided in such a formas to surround each of the LED element resting regions 14 of the leadframe body 11.

In the present embodiment, a metallic layer (in this case, avapor-deposited aluminum layer or sputtered aluminum layer) 12 isprovided on upper surfaces of each LED element resting region 14 of thelead frame body 11. The metallic layer 12 is also provided on the innerwalls 23 b of the reflecting resin section 23. That is to say, thevapor-deposited aluminum layer or sputtered aluminum layer 12continuously extends along the inner walls 23 b of the reflecting resinsection 23 from the surface of the LED element resting region 14. Thevapor-deposited aluminum layer or sputtered aluminum layer 12 is shownin hatched form in FIG. 12. The metallic layer 12 formed on the innerwalls 23 b of the reflecting resin section 23 as well as on the surfaceof the LED element resting region 14 is not limited to a vapor-depositedaluminum layer or sputtered aluminum layer and may include layers ofsilver, rhodium, palladium, platinum, copper, and/or the like.

In this case, the vapor-deposited aluminum layer or sputtered aluminumlayer 12, unlike that of the resin-attached lead frame 10 shown in FIGS.3 and 4, is not provided between the lead frame body 11 and thereflecting resin section 23. Instead, the vapor-deposited aluminum layeror sputtered aluminum layer 12 is provided only in each LED elementresting region 14 on the surface of the lead frame body 11.

In addition, as shown in FIG. 12, in order to prevent short-circuitingbetween the die pad 25 and the lead portion 26, the vapor-depositedaluminum layer or sputtered aluminum layer 12 is not provided on asection adjacent to a space 17, on the inner walls 23 b of thereflecting resin section 23.

The resin-attached lead frame 10A is substantially of the sameconfiguration as that of the resin-attached lead frame 10 shown in FIGS.3 and 4, and detailed description of the lead frame configuration istherefore omitted herein.

While in the present embodiment the lead frame body 11 includes the diepads 25 and the lead portions 26 spaced from the die pads 25, the leadframe body 11 is not limited to this configuration and needs only toinclude at least one die pad 25 and one lead portion 26.

FIG. 17 shows a resin-attached lead frame 10A according to amodification of the present embodiment. In the resin-attached lead frame10A of FIG. 17, a reflecting metallic layer 51 is provided on an uppersurface 23C of the reflecting resin section 23. The reflecting metalliclayer 51 may be formed from a vapor-deposited aluminum layer orsputtered aluminum layer 12 or formed from other such kinds of metalliclayers as of silver, rhodium, palladium, platinum, and/or copper. When asemiconductor device 20 is built into an illumination device, part ofthe light emitted from the LED element 21 will commonly or may reflectfrom the illumination device and return to an upper section of thesemiconductor device 20. Providing the reflecting metallic layer 51 asdescribed above, however, prevents the light from being absorbed intothe semiconductor device 20 after the light has returned to the uppersection thereof.

FIG. 18 shows a resin-attached lead frame 10A according to anothermodification of the present embodiment. The resin-attached lead frame10A shown, in FIG. 18 differs from that of the modification shown inFIG. 17, in that a reflecting metallic layer 51 is not provided at aregion 23 d on an upper surface 23 c of a reflecting resin section 23,the region 23 d being a section that will be later cut by dicing asshown in FIG. 9(e) and where the reflecting resin section 23 is exposed.The reflecting metallic layer 51 is provided at all other regions on theupper surface 23 c of the reflecting resin section 23. The section 23 dat which the reflecting resin section 23 is exposed may exist nearly ona central section of the upper surface 23 c of the reflecting resinsection 23 or on a position shifted in a horizontal direction from thecentral section of the upper surface 23 c. In this case, no foreignsubstances such as dicing swarf or metallic particles of the highlyelectroconductive aluminum or other materials will be included, whichwill in turn prevent short-circuiting due to any metallic foreignsubstances left after cutting.

FIG. 19 shows a resin-attached lead frame 10A according to yet anothermodification. The resin-attached lead frame 10A shown in FIG. 19, unlikethat of the modification shown in FIG. 17, has a recess 52 concavedinward nearly in a central portion of an upper surface 23 c of areflecting resin section 23. A reflecting metallic layer 51 is providedin an entire internal region of the recess 52 (including a base 52 a) inFIG. 19. Since a reflecting metallic layer 51 does not commonly exist ina section that has been cut by dicing, this section has a property ofabsorbing light. Additionally, when a semiconductor device 20 is builtinto an illumination device, part of the light emitted from the LEDelement 21 will commonly or may reflect from the illumination device andreturn to an upper section of the semiconductor device 20. Since theregion that absorbs the light (i.e., the section cut by dicing) isformed to have a small shape and size in FIG. 19, this geometry preventsthe light from being absorbed into the semiconductor device 20 after thelight has returned to the upper section thereof.

FIG. 20 shows a resin-attached lead frame 10A according to a furthermodification. The resin-attached lead frame 10A shown in FIG. 20 differsfrom that of the modification shown in FIG. 19, in that a reflectingmetallic layer 51 is not provided at a base 52 a of a recess 52, thebase 52 a being a section that will be later cut by dicing as shown inFIG. 9(e) and where a reflecting resin section 23 is exposed. Thereflecting metallic layer 51 is provided at all other regions of therecess 52. This configuration prevents light from being absorbed into asemiconductor device 20 after the light has returned to an upper sectionthereof. In addition, no foreign substances such as dicing swarf ormetallic particles of the highly electroconductive aluminum or othermaterials will be included, which will in turn prevent short-circuitingdue to any metallic foreign substances left after cutting.

Semiconductor Device Configuration

Next, a semiconductor device fabricated using the resin-attached leadframe shown in FIGS. 11 and 12 is described below per FIGS. 13 and 14.FIG. 13 is a sectional view of the semiconductor device (SON type), andFIG. 14 is a plan view thereof.

As shown in FIGS. 13 and 14, the semiconductor device 20A includes a(singulated) lead frame 15 having a lead frame body 11 and avapor-deposited aluminum layer or sputtered aluminum layer 12, an LEDelement 21 disposed on a die pad 25 of the lead frame 15, and a bondingwire (electric conductor) 22 that electrically interconnects the LEDelement 21 and a lead portion 26 of the lead frame 15.

In addition, a reflecting resin section 23 is provided around the LEDelement 21. Furthermore, the LED element 21 and the bonding wire 22 areboth sealed with a light-transmissive sealing resin 24.

Referring to FIGS. 13 and 14, in addition to upper surfaces of LEDelement resting regions 14 on the lead frame body 11, thevapor-deposited aluminum layer or sputtered aluminum layer 12 is furtherprovided on inner walls 23 b of the reflecting resin section 23. Thevapor-deposited aluminum layer or sputtered aluminum layer 12 is shownin hatched form in FIG. 14.

Besides, the semiconductor device 20A shown in FIGS. 13 and 14 hassubstantially the same configuration as that of the semiconductor device20 shown in FIGS. 5 and 6, and detailed description of the semiconductordevice configuration is omitted herein.

Method of Manufacturing the Resin-Attached Lead Frame

Next, a method of manufacturing the resin-attached lead frame 10A shownin FIGS. 11 and 12 is described below using FIGS. 15(a) to (f) and 16(a)to (d). The following description focuses mainly upon differences withrespect to the steps shown in FIGS. 7(a) to (g) and 8(a) to (c).

First as shown in FIG. 15(a) to (e), a lead frame body 11 having a diepad 25 and a lead portion 26 disposed away from the die pad 25 isfabricated in steps similar to those shown in FIG. 7(a) to (e).

Next, a lower surface of the lead frame body 11 is provided withelectrolytic plating to form a silver-plated layer 29 on each of a firstouter lead portion 27 and a second outer lead portion 28. Thus, as shownin FIG. 15(f), a lead frame 15 is obtained. At this time, the lead framebody 11 may alternatively have its entire surface plated with silver.

Next, a reflecting resin section 23 is formed on the surface of the leadframe body 11 to integrate the lead frame 15 and the reflecting resinsection 23, as shown in FIG. 16(a) to (c). The step of forming thereflecting resin section 23, shown in FIG. 16(a) to (c), issubstantially the same as the step of FIG. 8(a) to (c), except that thereflecting resin section 23 is formed before the vapor-depositedaluminum layer or sputtered aluminum layer 12 is formed.

Next as shown in FIG. 16(d), the LED element resting region 14 of thelead frame body 11 and the inner walls 23 b of the reflecting resinsection 23 are provided with aluminum vapor deposition or aluminumsputtering to form a vapor-deposited aluminum layer or sputteredaluminum layer 12. In this way, the resin-attached lead frame 10A shownin FIGS. 11 and 12 is obtained.

A method in which the semiconductor device 20A shown in FIGS. 13 and 14is fabricated using the thus-obtained resin-attached lead frame 10A issubstantially the same as the method shown in FIG. 9(a) to (f), anddetailed description of the fabrication method is omitted herein.

As set forth above, the present embodiment enhances the extractionefficiency of the light from the LED element 21 and prevents the leadframe 15 from degrading with time.

In accordance with the present embodiment, the vapor-deposited aluminumlayer or sputtered aluminum layer 12 is also provided on the inner walls23 b of the reflecting resin section 23. The aluminum constituting thevapor-deposited aluminum layer or sputtered aluminum layer 12 does notdegrade even when exposed to the ultraviolet radiation emitted from theLED element 21, such that the reflecting resin section 23 can beprevented from degrading even when exposed to the ultraviolet radiation.

The invention claimed is:
 1. A resin-attached lead frame, comprising: alead frame main body including: a plurality of die pads; a plurality oflead portions each spaced from a corresponding one of the plurality ofdie pads; and LED element resting regions each formed over an areaincluding an upper surface of one of the plurality of die pads and anupper surface of one of the plurality of lead portions; and a reflectingresin section surrounding each of the LED element resting regions of thelead frame main body; wherein: a vapor-deposited aluminum layer or asputtered aluminum layer to reflect a light from an LED element isprovided on upper surfaces of the LED element resting regions of thelead frame main body; each of the plurality of die pads and each of theplurality of lead portions are coupled to an adjacent die pad and/or anadjacent lead portion via a tie bar; the vapor-deposited aluminum layeror sputtered aluminum layer is further provided on an upper surface ofthe tie bar; the tie bar has a length direction, a width direction, anda thickness direction, the thickness direction being in a direction fromthe upper surface of the tie bar to a lower surface of the tie bar thatis opposite to the upper surface, and the length and width directionsbeing perpendicular to each other and defining a plane that isorthogonal to the thickness direction; and the tie bar is interposed inthe thickness direction between portions of the reflecting resinsection.
 2. The resin-attached lead frame according to claim 1, whereinthe vapor-deposited aluminum layer or the sputtered aluminum layer isfurther provided on an inner wall of the reflecting resin section. 3.The resin-attached lead frame according to claim 1, wherein theplurality of LED element resting regions of the lead frame main body arearranged lengthwise and breadthwise.
 4. The resin-attached lead frameaccording to claim 1, wherein: the lead frame main body is formed fromany one of copper, a copper alloy, and a 42-alloy, and at least theupper surfaces of the LED element resting regions are worked into amirror-like finish having a roughness level of 0.01 μm to 0.10 μm inarithmetic average height “Sa,” and 2 μm to 18 μm in roughnesscurvilinear element average length “Sm”.
 5. The resin-attached leadframe according to claim 1, wherein a silver-plated layer is provided ona lower surface of each of the plurality of lead portions as well as ona lower surface of each of the plurality of die pads of the lead framemain body.
 6. The resin-attached lead frame according to claim 1,wherein grooves for enhancing adhesion between the lead frame main bodyand the reflecting resin section are formed on an upper surface of thelead frame main body.
 7. The resin-attached lead frame according toclaim 1, wherein a reflecting metallic layer is provided on an uppersurface of the reflecting resin section.
 8. The resin-attached leadframe according to claim 7, wherein: the upper surface of the reflectingresin section has a part that is cut by dicing, and the reflecting resinsection is exposed at the part.
 9. The resin-attached lead frameaccording to claim 7, wherein an inward concaved recess is formed on theupper surface of the reflecting resin section.
 10. The resin-attachedlead frame according to claim 1, wherein an entirety of the uppersurface of the tie bar and an entirety of the lower surface of the tiebar are covered by the reflecting resin section.
 11. A resin-attachedlead frame, comprising: a lead frame main body including: a die pad; alead portion disposed apart from the die pad; and an LED element restingregion formed over an area including an upper surface of the die pad andan upper surface of the lead portion; and a reflecting resin sectionsurrounding the LED element resting region of the lead frame main body;wherein: a vapor-deposited aluminum layer or a sputtered aluminum layerto reflect a light from an LED element is provided on an upper surfaceof the LED element resting region of the lead frame main body; the diepad and the lead portion are each coupled to an outer frame via a tiebar; the vapor-deposited aluminum layer or sputtered aluminum layer isfurther provided on an upper surface of the tie bar; the tie bar has alength direction, a width direction, and a thickness direction, thethickness direction being in a direction from the upper surface of thetie bar to a lower surface of the tie bar that is opposite to the uppersurface, and the length and width directions being perpendicular to eachother and defining a plane that is orthogonal to the thicknessdirection; and the tie bar is interposed in the thickness directionbetween portions of the reflecting resin section.
 12. The resin-attachedlead frame according to claim 11, wherein an entirety of the uppersurface of the tie bar and an entirety of the lower surface of the tiebar are covered by the reflecting resin section.
 13. A lead framecomprising: a lead frame main body including: a plurality of die pads; aplurality of lead portions each spaced from a corresponding one of theplurality of die pads; and LED element resting regions each formed overan area including an upper surface of one of the plurality of die padsand an upper surface of one of the plurality of lead portions; wherein:a vapor-deposited aluminum layer or a sputtered aluminum layer toreflect a light from an LED element is provided on upper surfaces of theLED element resting regions of the lead frame main body; each of theplurality of die pads and each of the plurality of lead portions arecoupled to an adjacent die pad and/or an adjacent lead portion via a tiebar, and the vapor-deposited aluminum layer or sputtered aluminum layeris further provided on the tie bar.
 14. A lead frame comprising: a leadframe main body including: a die pad; a lead portion disposed apart fromthe die pad; and an LED element resting region formed over an areaincluding an upper surface of the die pad and an upper surface of thelead portion; wherein: a vapor-deposited aluminum layer or a sputteredaluminum layer to reflect a light from an LED element is provided on anupper surface of the LED element resting region of the lead frame mainbody; the die pad and the lead portion are coupled to an outer frame viaa tie bar; and the vapor-deposited aluminum layer or sputtered aluminumlayer is further provided on the tie bar.
 15. A method for manufacturinga resin-attached lead frame, the method comprising: providing a leadframe main body including: a plurality of die pads; a plurality of leadportions each spaced from a corresponding one of the plurality of diepads; and LED element resting regions each formed over an area includingan upper surface of one of the plurality of die pads and an uppersurface of one of the plurality of lead portions; providing avapor-deposited aluminum layer or a sputtered aluminum layer to reflecta light from an LED element on upper surfaces of the LED element restingregions of the lead frame main body; and providing a reflecting resinsection surrounding each of the LED element resting regions of the leadframe main body; wherein: each of the plurality of die pads and each ofthe plurality of lead portions are coupled to an adjacent die pad and/oran adjacent lead portion via a tie bar; the vapor-deposited aluminumlayer or sputtered aluminum layer is further provided on an uppersurface of the tie bar; the tie bar has a length direction, a widthdirection, and a thickness direction, the thickness direction being in adirection from the upper surface of the tie bar to a lower surface ofthe tie bar that is opposite to the upper surface, and the length andwidth directions being perpendicular to each other and defining a planethat is orthogonal to the thickness direction; and the tie bar isinterposed in the thickness direction between portions of the reflectingresin section.
 16. The method according to claim 15, wherein an entiretyof the upper surface of the tie bar and an entirety of the lower surfaceof the tie bar are covered by the reflecting resin section.
 17. A methodfor manufacturing a resin-attached lead frame, the method comprising:providing a lead frame main body including: a plurality of die pads; aplurality of lead portions each spaced from a corresponding one of theplurality of die pads; and LED element resting regions each formed overan area including an upper surface of one of the plurality of die padsand an upper surface of one of the plurality of lead portions; providinga reflecting resin section surrounding each of the LED element restingregions of the lead frame main body; and providing a vapor-depositedaluminum layer or a sputtered aluminum layer to reflect a light from anLED element on an inner wall of the reflecting resin section as well ason upper surfaces of the LED element resting regions of the lead framemain body; wherein: at least one of the plurality of die pads and atleast one of the plurality of lead portions are coupled to an outerframe via a tie bar; the vapor-deposited aluminum layer or sputteredaluminum layer is further provided on an upper surface of the tie bar;the tie bar has a length direction, a width direction, and a thicknessdirection, the thickness direction being in a direction from the uppersurface of the tie bar to a lower surface of the tie bar that isopposite to the upper surface, and the length and width directions beingperpendicular to each other and defining a plane that is orthogonal tothe thickness direction; and the tie bar is interposed in the thicknessdirection between portions of the reflecting resin section.
 18. Themethod according to claim 17, wherein an entirety of the upper surfaceof the tie bar and an entirety of the lower surface of the tie bar arecovered by the reflecting resin section.